Interlocking Rolled Garage Floor Cover System

ABSTRACT

A floor cover system includes a cover panel having a preformed end and a connector strip having a first and second receptacles adapted to receive the preformed end of the cover panel. An inner surface of the receptacle of the connector strip has a portion that is complementary in shape to that of a surface of the preformed end.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/263,926, entitled INTERLOCKING ROLLED GARAGE FLOOR COVER SYSTEM, filed on Nov. 24, 2009, the disclosure of which is incorporated herein by reference in its entirety.

FIELD OF INVENTION

The present invention relates generally to cover panels and, in particular, to a method of interlocking cover panels.

BACKGROUND OF INVENTION

Several types of modular, interlocking floor coverings have been developed and are generally suitable for use as garage flooring or playing surfaces. Modular, interlocking floor tiles, which are connected in a grid-like configuration, have an underside that is typically configured with a cross pattern of grid surfaces and support legs. The interlocking portion comprises a laterally extending loop member which is adapted to receive a lug member on an adjacent panel to mount the adjacent panel thereto. Examples of such modular floor covering are shown in Forlenza, U.S. Pat. No. 4,054,987 and Menconi et al., U.S. Pat. No. 4,436,779.

Despite the growing popularity of these interlocking plastic tile floor coverings, their use has been generally limited to rigid, square tile pieces. While this configuration has been acceptable for rigid tiles, it is generally not suitable for large rolled pieces of floor covering. But large rolled pieces of flooring, which may be provided as a single sheet or mat to cover an entire garage floor, are impractical due to their large size and weight. Thus, a need exists for joining or interlocking several pieces of rolled flooring.

SUMMARY OF THE INVENTION

In one embodiment of the invention, a cover system is provided comprising a cover panel comprising a preformed end having a first surface and a second surface; and a connector strip having a first channel and a second channel, the first and second channels each adapted to receive the preformed end of the cover panel, wherein at least a portion of an inner surface of the first and second channels is approximately complementary in shape to that of the first and/or second surface of the preformed end to facilitate interconnecting the cover panel with the connector strip.

In another embodiment of the invention, a method of constructing a cover system is provided that includes obtaining a first cover panel, the cover panel comprising at least one preformed end having a first surface and a second surface. The method further includes obtaining a connector strip having at least a first receptacle adapted to receive the at least one preformed end of the first cover panel, wherein at least a portion of an inner surface of the first receptacle is approximately complementary in shape to that of the first and/or the second surface of the at least one preformed end. The method also includes inserting the at least one preformed end of the first cover panel into the first receptacle of the connector strip.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial perspective view of a connector strip and two cover panels according to one embodiment of the present invention.

FIG. 2 is an end view of the connector strip and the cover panels shown in FIG. 1.

FIG. 3 is a perspective view of a section of a cover panel according to one embodiment of the present invention.

FIG. 4 is an enlarged end view of a connector strip according to one embodiment of the present invention.

FIG. 5 is a top perspective view of a cover system according to one embodiment of the present invention.

FIG. 6 is a perspective view of a connector strip and two cover panels according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made to the various Figures wherein like numbers represent like parts. Referring to FIGS. 1-2, embodiments of the present invention are directed to a cover system 10 and to a method for connecting two or more similar cover panels 12, 14 together to form the cover system 10.

According to embodiments of the invention, a first cover panel 12 may be connected to a second cover panel 14 using a connector strip 16.

According to embodiments of the invention, the first and second cover panels 12, 14 may comprise any suitable material, such as natural or synthetic polymers, including thermosetting and thermoplastic compositions, and the like. The material may be selected based on the desired final properties, such as durability or flexibility, or the intended use, such as for use as a garage floor cover. As used herein, “flexible” is understood to allow the cover panels 12, 14 to be rolled up into a storage or shipping configuration and have sufficient weight to lie in a substantially flat condition when being installed and in use. That is, the cover panels 12, 14 may be bent, twisted, turned, or bowed and are capable of withstanding any of the aforementioned stresses without damage to the cover panels 12, 14 or any elements thereof. According to embodiments of the invention, the cover panels 12, 14 are flexible cover panels.

The cover panels 12, 14 each have at least one preformed end 22, 24, respectively, that is useful for connecting the two cover panels 12, 14 together with the connector strip 16. Each preformed end 22, 24 comprises a first surface 22 a, 24 a and a second surface 22 b, 24 b. According to embodiments of the present invention, at least one surface of the preformed ends 22, 24 may be shaped, textured, or a combination thereof to facilitate interconnecting cover panels 12, 14 with connector strip 16. For example, at least one surface may have one or more rows of spaced apart beveled channels, or may be serrated or corrugated. According to another embodiment, the first surfaces 22 a, 24 a and the second surfaces 22 b, 24 b may be shaped, textured, or a combination thereof to facilitate interconnecting cover panels 12, 14 with connector strip 16.

As shown in FIGS. 1-2, the preformed ends 22, 24 may be shaped on only one surface to facilitate interconnecting cover panels 12, 14 with connector strip 16. In this embodiment, the preformed ends 22, 24 may comprise first surfaces 22 a, 24 a having one or more beveled channels 26 and smooth second surfaces 22 b, 24 b. In an alternative embodiment, both the first 22 a, 24 a and the second 22 b, 24 b surfaces are shaped to facilitate interconnecting cover panels 12, 14 with connector strip 16. For example, the preformed end 22 may comprise a first surface 22 a and a second surface 22 b having one or more beveled channels 26.

As shown in FIG. 3, a cover panel may comprise a first preformed end 32 and a second preformed end 34, which thereby enables the joining of at least two additional cover panels with the cover panel 30 lying in the center position of three panels.

Referring again to FIGS. 1-2, and referring further to FIG. 4, the connector strip 16 comprises a first receptacle 36 and second receptacle 38 adapted to receive the preformed ends 22, 24 of the cover panels 12, 14, wherein at least a portion of the inner surface of the first and second receptacle is complementary in shape to that of the first surface 22 a, 24 a and/or the second surface 22 b, 24 b of the preformed ends. The first and second receptacles 36, 38 of the connector strip 16 may be positioned such that they are opposed to each other such that connector strip 16 has a generally H-shaped cross-section, as depicted in FIGS. 2 and 4. For example, as shown in FIG. 4, the connector strip 16 may have a first wall 40 and a second wall 42 connected by an orthogonal central beam 44. In an alternative embodiment that is not shown, the connector strip may comprise two U-shaped channels, which are connected at the closed end of each of the U-shaped channels. In yet another embodiment, the connector strip 16 is a unitary structure.

The connector strip 16 may comprise any suitable material, such as natural or synthetic polymers. For example, polyvinyl chloride (PVC), thermoplastic rubber (TPR), or a thermoplastic polymer may be used. The connector strip 16 may be rigid. Alternatively, the connector strip 16 may be sufficiently flexible to allow elastic expansion of the receptacle walls 40, 42, thereby accommodating the insertion of the preformed ends 22, 24 into the receptacles 36, 38.

In the embodiment shown in FIG. 1, each cover panel 12, 14 has a preformed end 22, 24 with beveled channels 26 running generally parallel to the preformed ends. A connector strip 16 is configured to provide receptacles having a complementary configuration for accommodating the beveled channels 26. The complementary configuration of the preformed ends 22, 24 and the connector strip 16 facilitates a synchronized fit with the connector strip 16 when the preformed ends 22, 24 are inserted, in the directions indicated by arrows A and B, into the receptacles 36, 38 of the connector strip 16. The complementary fit between the preformed ends 22, 24 and the connector strip 16 operates to ensure that the two cover panels 12, 14 stay connected by maintaining the preformed ends 22, 24 in the connecting strip 16. Two cover panels 12, 14 and a connector strip 16 are shown fully assembled in FIG. 5.

The connector strip 16 and cover panels 12, 14 combination is suitable for covering designed or textured surfaces, and is adaptable for all surface sizes. For example, standard-sized cover panels 12, 14, having a width of about 7.5 feet or about 2.3 meters, may be connected according to the present invention. Alternatively, a wide cover panel 12, 14 may be split into smaller width cover panels 12, 14, e.g. about 3.75 feet or about 1.1 meters, and then joined through the use of a connector strip 16. Moreover, the cover panel 12 and the connecting strip 16 may be formed according to any suitable manufacturing process, such as calendaring, extrusion, injection molding, or thermoforming.

While the present invention has been illustrated by the description of one or more embodiments, and while the embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative product and method and illustrative examples shown and described. The various features of exemplary embodiments described herein may be used in any combination. Accordingly, departures may be made from such details without departing from the scope of the general inventive concept. 

1. A floor cover system comprising: a cover panel comprising a preformed end having a first surface and a second surface; and a connector strip having a first channel and a second channel, the first and second channels each adapted to receive the preformed end of the cover panel, wherein at least a portion of an inner surface of the first and second channels is approximately complementary in shape to that of the first and/or second surface of the preformed end to facilitate interconnecting the cover panel with the connector strip.
 2. The floor cover system of claim 1, wherein the cover panel comprises two preformed ends.
 3. The floor cover system of claim 1, wherein at least the first surface of the preformed end is serrated, corrugated, or comprises one or more rows of beveled channels.
 4. The floor cover system of claim 3, wherein at least the first surface of the preformed end comprises one or more rows of beveled channels.
 5. The floor cover system of claim 1, wherein at least the first surface of the preformed end is shaped, textured or a combination thereof.
 6. The floor cover system of claim 1, wherein the first surface and the second surface of the preformed end are shaped, textured, or a combination thereof.
 7. The floor cover system of claim 1, wherein the cover panel is flexible and comprises a thermosetting or thermoplastic polymer.
 8. The floor cover system of claim 1, wherein the first and second receptacles of the connector strip are positioned on oppositely disposed ends of the connector strip.
 9. The floor cover system of claim 1, wherein the connector strip comprises a first wall and a second wall connected by an orthogonal central beam thereby defining the first and second receptacles.
 10. The floor cover system of claim 1, wherein the connector strip comprises two U-shaped channels connected at the closed end of each of the U-shaped channels.
 11. A method of constructing a floor cover system comprising: obtaining a first cover panel, the cover panel comprising at least one preformed end having a first surface and a second surface; obtaining a connector strip having at least a first receptacle adapted to receive the at least one preformed end of the first cover panel, wherein at least a portion of an inner surface of the first receptacle is approximately complementary in shape to that of the first and/or the second surface of the at least one preformed end; and inserting the at least one preformed end of the first cover panel into the first receptacle of the connector strip.
 12. The method of claim 11, wherein the connector strip further comprises a second receptacle, the method further comprising: obtaining a second cover panel having at least one preformed end; and inserting the at least one preformed end of the second cover panel into the second receptacle of the connector strip.
 13. The method of claim 11, wherein the cover panel comprises two preformed ends.
 14. The method of claim 11, wherein at least the first surface of the at least one preformed end is serrated, corrugated, or comprises one or more rows of beveled channels.
 15. The method of claim 14, wherein at least the first surface of the at least one preformed end comprises one or more rows of beveled channels.
 16. The method of claim 11, wherein at least the first surface of the at least one preformed end is shaped, textured, or a combination thereof.
 17. The method of claim 11, wherein the first surface and the second surface of the at least one preformed end are shaped, textured, or a combination thereof.
 18. The method of claim 11, wherein the first and second receptacles of the connector strip are positioned on oppositely disposed ends of the connector strip.
 19. The method of claim 11, wherein the connector strip further comprises a first wall and a second wall connected by an orthogonal central beam, thereby defining the first and second receptacles.
 20. The method of claim 11, wherein the connector strip comprises two U-shaped channels connected at the closed end of each of the U-shaped channels. 